Profile roof tile with integrated photovoltaic module

ABSTRACT

A roofing module provides weather protection generates electrical power. The module comprises a base having a plurality of curved crests and curved pans. The crests and pans have contours sized and shaped to match the size and shape of the contours and pans of conventional clay or concrete S-tiles to enable the base to interlock with the conventional clay or concrete S-tiles. The base is made from lightweight plastic material. Each crest of the base includes a depressed portion. A photovoltaic panel is positioned in the depressed portions of at least two curved crests and span across at least one curved pan between the at least two curved crests.

RELATED APPLICATIONS

The present application claims the benefit of priority under 35 U.S.C. §119(e) to the following provisional applications:

U.S. Provisional Application No. 60/806,445, filed on Jun. 30, 2006;

U.S. Provisional Application No. 60/806,528, filed on Jul. 3, 2006;

U.S. Provisional Application No. 60/807,501, filed on Jul. 17, 2006;

U.S. Provisional Application No. 60/820,334, filed on Jul. 25, 2006; and

U.S. Provisional Application No. 60/871,988, filed on Dec. 27, 2006.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to solar panels for generating electrical energy and more particularly relates to solar modules integrated into profile (contoured) roof tiles.

2. Description of the Related Art

Conventional solar panels for generating electrical power for residences are flat and are placed on a portion of the roof that faces the sun during midday. Originally, the solar panels were mounted over existing roofing materials (e.g., shingles) and formed a generally unaesthetic addition to a home. In some areas, the solar panels were not permitted because of the unattractive appearance. Recently developed solar panels are constructed in sizes and shapes that can be mounted directly to the underlying roof structure as replacements for flat roofing materials (e.g., flat concrete tiles) such that the solar panels provide the dual purpose of generating electrical power in response to sunlight and of providing protection from moisture intrusion while integrating in an aesthetically pleasing way with the roof system.

Because of the flat nature of conventional solar panels, such flat solar panels may be acceptable for roofs with flat roofing tiles as the primary roofing materials; however, when the flat solar panels are mounted on roofs that are otherwise protected with profile (e.g., contoured non-flat tiles), the flat areas occupied by the solar panels stand out visually. As used herein, profile tiles (e.g., non-flat or contoured tiles) refer to “S” tiles, low-profile tiles, and similar non-flat tiles that have a lower portion (e.g., a concave portion in an elevation view) and a higher portion (e.g., a convex portion in an elevation view) that form alternating crests and valleys, for example. Such tiles are also referred to as “profile” tiles to distinguish the tiles from conventional flat tiles. When such profile (contoured) tiles are installed on roofs, a lower portion of each succeeding vertical course of profile tiles overlaps an upper portion of the previous course with the elevated portions (e.g., crests) of the profile tiles in the higher row fitting over the elevated portions of the profile tiles in the lower row and with the valleys of the profile tiles in the higher course fitting into the valleys of the profile tiles of the lower course. Accordingly, the flat portions of the solar panels stand out in stark contrast to the surrounding profile tiles.

The flat solar panels create significant construction issues at the transitions between the profile tiles and the flat solar panels. In particular, the continuity in the water protection provided by the overlapping tiles is interrupted at each transition since the solar panels do not have contours that conform to the contours of the profile tiles in the next lower row.

SUMMARY OF THE INVENTION

The profile (contoured) solar panel tile described herein and illustrated in the attached drawings enables the electricity-generating solar panel to be included in a seamless application with any conventional profile tile because the solar panel is advantageously embodied in a shape and size of a conventional profile tile, such as, for example, a concrete or clay “S” tile, a concrete low-profile tile, or a profile tile constructed from other materials or in other shapes. As discussed herein, the size and shape of the profile solar panel tile may be adapted to the size and shape of profile tiles from a number of different manufacturers. The size and shape of the profile solar panel tile enables the same roofing mechanic who installs the conventional roofing tiles to install the profile solar panel tile without any special tools or fasteners. In particular, the profile solar panel tiles have crests and valleys that conform to the crests of valleys of conventional tiles in adjacent courses (e.g., conventional tiles above or below the profile solar panel tiles). The profile solar tiles also interlock with or overlap with adjacent conventional tiles when installed in the same course. The adjacent tiles may be other profile solar panel tiles or conventional profile roofing tiles.

BRIEF DESCRIPTION OF THE DRAWINGS

Certain aspects in accordance with embodiments of the present invention are described below in connection with the accompanying drawing figures in which:

FIG. 1 illustrates a perspective view of a first embodiment of a profile (contoured) solar panel tile and portions of adjacent profile solar panel tiles installed onto a roof in the place of conventional profile (contoured) tiles (e.g., “S” tiles);

FIG. 2 illustrates an enlarged perspective view of the area of the profile solar panel tile within the circle 2 of FIG. 1 to show the position of the solar module in the solar module support tray;

FIG. 3 illustrates an enlarged perspective view of the area of the profile solar panel tile within the circle 3 of FIG. 1 to show the junction of two profile solar panel tiles shown in FIG. 1;

FIG. 4 illustrates a further enlarged perspective view of the area of the junction of the two profile solar panel tiles within the circle 4 in FIG. 3 to show the interlocking of the ends of the solar modules of the two profile solar panel tiles;

FIG. 5 illustrates the profile solar panel tiles of FIG. 1 in combination with conventional concrete “S” tiles;

FIG. 6 illustrates a profile tile solar panel configured with a contoured shape and a size to replace a plurality (e.g., three) of conventional clay “S” tiles;

FIG. 7 illustrates a perspective view of a second embodiment of a profile solar panel tile configured for injection molding;

FIG. 8 illustrates a perspective view of two solar panel tiles in accordance with the second embodiment in FIG. 7 positioned with the panel bases and the panel frames interlocked;

FIG. 9 illustrates an exploded perspective view of the profile solar panel tile of FIG. 7 looking from the top of the assembly showing the panel base, the panel base, the photovoltaic panel and the wiring junction box;

FIG. 10 illustrates an exploded perspective view of the profile solar panel tile of FIG. 7 looking from the bottom of the assembly;

FIG. 11 illustrates a top plan view of the two adjacent solar tile panels of FIG. 8;

FIG. 12 illustrates an elevational view of the two adjacent solar tile panels of FIG. 8;

FIG. 13 illustrates a cross-sectional view of the two adjacent solar tile panels of FIG. 8 taken along the lines 13-13 in FIG. 11;

FIG. 14 illustrates a cross-sectional view of the two adjacent solar tile panels of FIG. 8 taken along the lines 14-14 in FIG. 11;

FIG. 15 illustrates a perspective view of the solar tile panel base of FIG. 9 rotated to show the openings in the crests to receive the protrusions of the solar panel frame;

FIG. 16 illustrates an enlarged perspective view of the portion of the panel base of FIG. 9 within the circle 16 in FIG. 15;

FIG. 17 illustrates two rows of solar tile panels in accordance with the second embodiment of FIG. 7 with the lower portions of the solar tile panels in the upper row overlapping the upper portion of the solar tile panels in the lower row;

FIG. 18 illustrates a perspective view of an embodiment of a photovoltaic panel advantageously incorporated into the solar panel tile of FIGS. 1-6 and the solar panel tile of FIGS. 7-17;

FIG. 19 illustrates an enlarged cross-sectional view of the photovoltaic panel of FIG. 18 taken along the lines 19-19 in FIG. 18; and

FIG. 20 illustrates an exploded perspective view of the photovoltaic panel of FIG. 17.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

FIG. 1 illustrates a first profile (contoured) solar panel tile 100A in accordance with aspects of the present invention. FIG. 1 further illustrates a portion of a second profile solar panel tile 100B positioned at the left end of the first profile solar panel tile 100A and a portion of a third profile solar panel tile 100C positioned at the right end of the first profile solar panel tile 100A. As further illustrated in FIG. 1, a portion of a fourth profile solar panel tile 100D has a lower edge that overlaps the upper edges of portions of the first profile solar panel tile 100B and the third profile solar panel tile 100C.

In the embodiment illustrated in FIG. 1, the profile solar panel tile 100A comprises a profile structure 110A that is sized and shaped to conform to the approximate size and shape of a plurality (e.g., three) of abutting conventional profile tiles (“S” tiles) 114A, 114B, 114C when positioned on the roof of a building (see FIG. 5). In particular, in the illustrated embodiment, the profile structure 110A has a first end 120A (at the left in FIG. 1) and a second end 122A (at the right in FIG. 1) that are spaced apart by a distance that corresponds to the lateral distance occupied by the width of the three conventional profile tiles 114A, 114B, 114C (see FIG. 5) when the conventional profile tiles are installed on a roof and are interlocked to provide a water tight connection between the profile tiles.

In the illustrated embodiment, the profile structure 110A has a width of approximately 35 inches, which corresponds to the total width of three 12-inch wide conventional profile tiles (“S” tiles) overlapped approximately 0.5 inch at each interlock. The profile structure 110A has a height (viewed in the direction of the slope of a roof on which the structure is installed) of approximately 17 inches, which corresponds to the height of the conventional profile 114A, 11 4B, and 114C in FIG. 5.

The profile structure 110A has a thickness (viewed normal to a roof on which the structure is installed) of approximately 3 inches, which corresponds to the thickness of the conventional profile tiles (“S” tiles) 114A, 114B, 114C, shown in FIG. 5.

The profile structure 110A comprises three concave valleys (low portions) 130 and three convex crests (high portions) 132 between the first end 120A and the second end 122A. The valleys and crests extend between a bottom edge 134 and a top edge 136 of the profile structure 110A. The widths of the crests 132 (e.g., the chords across the arc forming the crests) are tapered from the lower edge to the upper edge so that the lower edge of the crests of one profile structure can be positioned over the upper edge of the crests of another profile structure.

In the illustrated embodiment, the valleys 130 and the crests 132 of the profile structure 1 10A are formed to have the sizes and shapes of the corresponding valleys and crests of conventional profile tiles (“S” tiles). In particular, the sizes and shapes of the valleys and crests are selected so that the supporting structure 110A can be positioned in an overlapping relationship with conventional profile tiles. For example, one or more rows of the profile solar panel tiles described herein can be substituted in place of a corresponding number of rows of conventional profile tiles. The lowermost row of profile solar panel tiles overlaps a next lower row of conventional profile tiles. A next higher row of conventional profile tiles overlaps the upper row of profile solar panel tiles. The profile solar panel tiles and the conventional profile tiles have a headlap of approximately 3-4 inches to conform to the overlap of conventional rows of profile tiles.

Although shown with a particular size and shape in FIG. 1, it should be understood that the profile solar panel tile 100 can be configured in a size and shape to be compatible with the sizes and shapes of conventional profile tiles from many different manufacturers so that the profile solar panel tile 100 can be installed in courses above or below such conventional tiles. The profile solar panel tile 100 can also be installed in the same course as conventional tiles. For example, in the illustrated embodiment, the profile structure 110A has the approximate dimensions of three adjacent conventional tiles, such as, for example, three MNLT “S” tiles, three Eagle “S” tiles, three Hanson “S” tiles, three Westile “S” tiles, or three “S” tiles from other manufacturers, which allows a roofing mechanic to install the profile solar panel tiles 100 in an overlapped relationship with the conventional tiles while maintaining the aesthetic appearance of the roof. It should be understood that the profile solar panel tiles 100 can be configured with sizes and shapes that correspond to the sizes and shapes of a variety of conventional profile tiles from other manufacturers so that the contours of the profile solar panel tiles 100 conform to the contours of the conventional profile tiles. The conventional profile tiles may comprise concrete, clay, or other commercially available roofing materials. For example, the profile solar panel tiles 100 may be configured in the size and shape of low-profile contoured tiles (not shown) or in the size and shape of one-piece clay tiles, such as, for example, the configuration illustrated in FIG. 6 (discussed below).

As illustrated in FIG. 1, the first (left) end 120A of the first profile solar panel tile 100A is interlocked with the second (right) end 122B of the second profile solar panel tile 100B. The second (right) end 122A of the first profile solar panel tile 100A is interlocked with the first (left) end 120C of the third profile solar panel tile 100C. It should be understood that either end of the first profile solar panel tile 100A will also interlock with the opposing end of a conventional profile tile in a row of tiles comprising both conventional profile tiles and profile solar panel tiles.

In FIG. 1, a first portion of the fourth profile solar panel tile 100D is positioned over an uppermost portion of the first profile solar panel tile 100A, and a second portion of the fourth profile solar panel tile 100D is positioned over an uppermost portion of the third profile solar panel tile 100C to form a running bond wherein the interlocked ends of the tiles in one row are offset with respect to the interlocked ends of the tiles in an adjacent row. The profile solar panel tiles can also be installed in a straight bond pattern with the interlocked ends between adjacent tiles in one row aligned with the interlocked ends of adjacent tiles in an adjacent row (see FIG. 17 described below). In the illustrated embodiment, the tiles have approximately 3 inches of vertical headlap. The headlap may be increased up to 4 inches to allow the roofing mechanic to adjust the headlap so that the top row of tiles at the ridge of the roof comprises full tiles. In general, the profile solar panel tiles 100 can be installed in a similar manner to a conventional contour roofing tile (e.g., S-tile), which the profile solar panel tile is intended to replace.

The structure 110A of the profile solar panel tile 100A advantageously comprises a polyvinylchloride (PVC) plastic material or other suitable lightweight durable material. The PVC plastic material is manufactured to with a color that corresponds to the base color of a corresponding conventional “S” tile of concrete or clay so that the structure 110A of the profile solar panel tile blends with the conventional “S” tiles when installed on a roof with conventional “S” tiles.

As further illustrated in the drawings, a solar module support tray 150A extends across the tops of the crests 132 of the profile structure 110A. In particular, the solar module support tray 150A is embedded in the crests 132 so that an upper surface of the solar module support tray 150A is even with the peaks of the crests 132 (see, for example, the enlarged drawing in FIG. 3). The solar module support tray 150A has a lower edge that is displaced from the lower edge of the profile structure 110A by approximately 0.25 inch so that a portion of the crest 132 constrains the lower edge of the solar module support tray 150A. In FIG. 1, the solar module support tray 150A has a height of approximately 12.25 inches along the crests 132 and has a width of approximately 34.25 inches. For example, the width of the solar module support tray 150A is slightly less than the width of the profile structure 110A. The height and width of the solar module support tray 150A can be varied in accordance with the height and width of the profile structure 110A, which may be varied to correspond to the height and width of the three commercial tiles emulated by the profile structure 110A.

In the illustrated embodiment, the solar module support tray 150A has a thickness of approximately 0.375 inch so that at the peak of each crest 132, the solar module support tray 150A is embedded in the crest 132 by approximately 0.375 inch. The solar module support tray 150A advantageously comprises PVC plastic or other suitable material. In certain advantageous embodiments, the solar module support tray 150A comprises the same material as the profile structure 110A and is formed (e.g., injection molded) as part of the profile structure 110A.

The solar module support tray 150A is generally rectangular as shown. As shown in FIG. 2 for a solar module support tray 150B on the second profile solar panel tile 100B, a central portion of the solar module support tray 150B is depressed by approximately 0.1875 inch to form a cavity 152 having a depth of 0.1875 inch. The cavity 152 has a height of approximately 12 inches and a width of approximately 34 inches to receive a photovoltaic module (solar module) 160B having a generally corresponding height and width and having a thickness of approximately 0.1875 inch. The undepressed outer perimeter of the solar module support tray 150A forms a wall around the solar module 160A with a wall thickness of approximately 0.125 inch. The solar module 160A lies in the depressed cavity of the solar module support tray 150A with an exposed surface of the solar module 160A coplanar with the undepressed perimeter walls of the solar module support tray 150A. The solar module 160A is secured in the solar module support tray 150A by a suitable adhesive (not shown). The dimensions of the solar module support tray 150A and the dimensions of the solar module 160A can be varied to correspond to different sizes and shapes of conventional tiles that the profile solar panel tile 100A is intended to emulate.

The solar module support tray 150A receives a similar solar module 160A. Similar solar modules 160C and 160D are shown for the third profile solar panel tile 100C and the fourth profile solar panel tile 100D. Each solar module includes a pair of electrical conductors (not shown) that are routed through the bottom of the respective solar module support tray and through the crests of the underlying profile structure. The openings through the material of the solar module support tray and the profile structure are sealed with a waterproof material. The electrical conductors from the solar modules and a plurality of other solar modules are interconnected in a conventional manner to communicate the electrical power from the solar modules to a combiner box (not shown). For example, a plurality of solar modules are interconnected to provide a desired voltage. The voltages from a set of interconnected solar modules and a plurality of additional sets of interconnected solar modules are combined in a known manner to provide a source of electrical power.

Preferably, the left end of the solar module support tray 150A and the right end of the solar module support tray 150B are interlocked. One interlocking system is illustrated in FIGS. 3 and 4, wherein the right end of the solar module support tray 150B includes a groove 170 formed therein, and the left end of the solar module support tray 150A includes a corresponding tongue 172. When adjacent profile structures 110 are positioned on a roof, the tongue 172 of a right profile structure 110 is positioned in the groove 170 of a left profile structure 110 to assist in maintaining adjacent solar module support trays 150 in coplanar relationship. A more preferred interlocking system is illustrated below in connection with an embodiment shown in FIGS. 7-17

Aesthetically, the profile solar panel tile shown in the accompanying drawings is unlike anything else on the market. In particular, the profile solar panel tile is advantageously constructed with shapes, sizes and colors to correspond to the shapes sizes and colors of existing concrete or clay “S” tiles or tiles with other distinct contours. In contrast, the “flat” profile solar panels that are currently on the market tie into the conventional “S” profile tiles with a combination of pan and cover metal flashings to keep the water off the underlayment. Unlike, conventional “flat” profile solar panels, no special flashings are required for the profile solar panel tiles to make the completed roof water tight because the profile solar panel tiles overlap with the conventional concrete “S” tiles in a manner similar to the manner in which rows of conventional “S” tiles overlap.

From the ground looking up at the roof, the profiles of the contoured solar panel tiles look substantially the same as if there were no solar tiles on the roof. Other products that are currently on the market create a flat depression in the field of the roof that is about 3 inches deep, which interrupts the profile of the roof system and is aesthetically unpleasing.

Embedding the solar module into the top portion of the profile solar panel tile helps hide the solar module behind the contoured profile of the conventional concrete or clay profile tiles on lower rows of tiles when looking up at the roof from the ground. At the same time, the embedded solar modules at the crests of the profile solar panel tiles still allow water to flow down the “pans” (e.g., the valleys) of the profile solar panel tiles uninterrupted, as illustrated by the continuous valleys shown in FIG. 5.

As discussed above, the solar module can also be incorporated into a plastic tile or a tile comprising another lightweight material configured to have the size, shape and appearance of a plurality (e.g., three) low-profile “Mediterranean” style tiles having a shallower water channel. In particular, one profile solar panel tile in accordance with the present invention fits in the space that would be occupied by two or more (e.g., three) low-profile tiles such as, for example, the single conventional low-profile tile (not shown). Accordingly, the low-profile solar panel tile overlaps with the conventional concrete low-profile roof tiles and maintains the continuity of the crests and valleys to maintain the overall visual impression of the conventional tiles.

The solar module may also be incorporated into other structures having a profile that emulates the appearance of other conventional concrete or clay roofing tiles. For example, FIG. 6 illustrates a portion of a roof having a plurality of conventional one-piece clay tiles 210, 212, 214, 216 in a first course of tiles. A first profile solar panel tile 220, a second profile solar panel tile 222 and a third profile solar panel tile 224 in a second course overlap with respect to the conventional tiles in the first course to form a headlap of substantially the same length as the headlap formed between adjacent courses of conventional tiles. A fourth profile solar panel tile 226 in an third course of tiles overlaps with the two profile solar panel tiles in the second course to form a headlap between the two courses. The profile solar panel tiles 220, 222, 224, 226 include respective solar modules 230, 232, 234, 236 across the crests. Preferably, the height and width of each solar module is selected to cover a substantial portion of the exposed crests of the respective profile solar panel tiles. As illustrated, the first profile solar panel tile 220 has a width corresponding to the width of three conventional one-piece clay tiles (e.g., the tiles 212, 214, 216 in the first course).

FIGS. 7-15 illustrate a more detailed embodiment of a profile solar panel tile 300 in accordance with an embodiment suitable for production using injection molding techniques. As illustrated in the top view in FIG. 7, the solar panel tile 300 comprises an S-tile roofing panel base 302. The panel base 302 comprises a plurality of crests 304, 306, 308 and pans 312, 314, 316 as described above for the other embodiments. As shown in FIG. 9, the crests 304, 306, 308 have respective depressed, flat areas 322, 324, 326, which are positioned to receive a solar cell array panel assembly 330. The depressed areas 322, 324, 326 are depressed by approximately 0.45-0.5 inch from the tops of the respective crests 304, 306, 308.

In the preferred embodiment, the panel base 302 of each solar panel tile has a height from a lower edge 340 to an upper edge 342 of approximately 17 inches and has a width from a left side 344 to a right side 346 of approximately 35.5-36 inches. The panel base 302 has a height of approximately 3.4-3.5 inches.

Each panel base 302 has a left interlock 350 and a right interlock 352. As shown in FIG. 8, when a first (left) solar panel tile 300A and a second (right) solar panel tile 300B are positioned side-by-side, the right interlock 352 of the panel base 302 of the left solar panel tile 300A receives the left interlock 350 of the panel base 302 of the right solar panel tile 300B, which causes the panel bases 302 of the two solar panel tiles 300A, 300B to overlap by approximately 0.8-0.85 inch. Because of the overlap of the interlocks 350, 352, each solar panel tile 300A, 300B has an effective width of approximately 34.65-35.2 inches when the respective panel bases 302 are interlocked as shown in FIG. 8.

As shown in FIG. 9, the depressed areas 322, 324, 326 are offset with respect to the upper edge 342 of the panel base 302 by approximately 4.1-4.15 inches and are offset from the lower edge 340 by approximately 0.45-0.5 inch such that the depressed, flat areas have a length of approximately 12.35-12.45 inches to receive the solar panel assembly 330. As illustrated, both the lower edge 340 and the upper edge 342 retain the contour of the S-tile.

As shown in the bottom view in FIG. 10, the panel base 302 of the profile solar panel tile 300 includes a plurality of horizontal strengthening ribs 360 and vertical strengthening ribs 362. The ribs 360, 362 provide sufficient strength to allow the panel base 302 to be constructed from relatively thin plastic material (e.g., approximately 0.125 inch in thickness).

As further shown in FIG. 10, the panel base 302 further comprises a plurality of spacer ribs 364 (e.g., six spacer ribs 364) which correspond to the spacer ribs on conventional clay or concrete S-tiles so that the solar panel S-tile maintains a substantially similar vertical position with respect to conventional tiles when installed on the same roof. For example, each spacer rib 364 has a height of approximately 0.5 inch, which is included in the overall height of 3.4-3.45 inches set forth above.

As shown in FIG. 9 for the illustrated embodiment, the panel base 302 further includes at least one vertically disposed fastener hole 370 in each crest 304, 306, 308 and at least one vertically disposed fastener hole 372 in each pan 312, 314, 316 proximate the upper edge 342 to receive a nail, screw, or other fastener to secure the panel base 302 to a roof (not shown). When the panel bases 302 are installed on a roof, the fastener holes 370, 372 are covered with overlapping portions of one or more tiles in a next higher row of tiles (either solar tiles as described herein or conventional tiles), as illustrated in FIG. 17.

As further shown in FIG. 9, the middle crest 306 further includes an opening 380 formed in the middle depressed area 324 proximate to the upper boundary of the depressed area 324. The opening 380 extends through the body of the panel base 302. The opening 380 can also be formed in either of the other depressed areas 322, 326.

As shown in the exploded view in FIG. 9, the solar array panel assembly 330 comprises a panel frame 400 and a photovoltaic (solar cell array) panel 402. The panel frame 400 is rectangular and has a height sized to fit in the depressed areas 322, 324, 326 and a width selected to be approximately equal to the width of the panel base 302. Accordingly, the frame 400 has a height between a lower edge 410 and an upper edge 412 that is slightly less than approximately 12.35-12.45 inches and has a width between a left edge 414 and a right edge 416 of approximately 35.5-36 inches. The frame 400 has a thickness of approximately 0.45-0.5 inch between a top 420 and a bottom 422, which generally corresponds to the depth of the depressed areas 322, 324, 326 so that the top 422 of the frame 400 is approximately flush with the tops of the crests 304, 306, 308, or slightly below or above the tops of the crests. The bottom 422 rests on the depressed areas 322, 324, 326. The bottom 422 includes a plurality of openings 424 that reduce the amount of material required to form the frame 400.

The top 420 of the frame 400 has a depressed central portion 426 that is generally rectangular in shape. The depressed central portion 426 is sized to form a rectangular rim having a lower wall 430 with a thicknesses of approximately 0.25 inch proximate the lower edge 410, having an upper wall 432 with a thicknesses of approximately 0.25 inch proximate the upper edge 412, having a left wall 434 with a thickness of approximately 1.5 inches proximate the left edge 414, and having a right wall 436 with a thickness of approximately 2.7 inches proximate the right edge 416. As illustrated, an upper portion of the left wall 434 is removed to form a left interlocking toothed portion 440, and a lower portion of the right wall 436 is removed to form a right interlocking toothed portion 442 that engage when the panel bases 302 of the adjacent profile solar panel tiles 300A, 300B are engaged as shown in FIG. 8.

The lower wall 430 of the frame 400 includes a plurality of protrusions 450, 452, 454, which are generally rectangular. The protrusions are sized and shaped to engage a respective opening 460, 462, 468 in the crests 304, 306, 308 proximate the respective lower ends of the depressed areas 322, 324, 326, and the lower edge 340 of the panel base 302, as shown in the FIGS. 15 and 16. In preferred embodiments, the portions of the crests around the openings are reinforced with additional material, as shown in FIG. 16. The frame 400 is positioned on the depressed areas 322, 324, 326 with the protrusions 350, 352, 354 engaged in the openings 460, 462, 464. The frame 400 is secured to the panel base 302 by a suitable adhesive, such as, for example, silicon adhesive. In addition, at least one of the crests 304, 306, 308 preferably includes an opening 470 formed in the wall forming the upper boundary of the respective depressed area 322, 324, 326. As shown in FIG. 14, the opening 470 receives a screw 472, which engages the upper wall 432 of the frame 400 to further secure the frame 400 to the base panel 302.

The depressed central portion 426 has a depth of approximately 0.2 inch. The depth is selected to receive the photovoltaic panel 402, which has a corresponding thickness. The depth of the depressed central portion 426 can be varied to accommodate photovoltaic panels having a greater thickness, such as, for example, the photovoltaic panel described below in connection with FIGS. 17, 19 and 20. The photovoltaic panel 402 has a length and width sized to fit in the depressed central portion 426 (e.g., approximately 12.3 inches by approximately 31.7 inches). The photovoltaic panel 402 may have a conventional construction comprising a plurality of cells connected in a selected series-parallel combination to produce a desired output voltage when solar energy is incident on the upper surface of the photovoltaic panel 402. In a particularly preferred embodiment, the photovoltaic panel 402 is constructed in the manner described in FIGS. 18, 19 and 20, described below. The photovoltaic panel 402 is secured in the frame 400 by a suitable weather-resistant adhesive, such as, for example, silicon adhesive.

The photovoltaic panel 402 includes at least a first panel output conductor 480 and a second panel output conductor 482, which exit the panel 402 and pass through one the openings 424 in the frame 400 and then through the opening 380 through the panel 402. The portion of the opening 380 not occupied by the panel output conductors 480, 482 is filed with a suitable weatherproof material, such as, for example, caulking and filler material. The solar array panel assembly 330 is secured to the panel base 300 with a suitable weatherproof adhesive, such as, for example, silicon adhesive.

As further shown in FIGS. 9, 10, 11 and 13, a junction box 500 is positioned on the underside of the panel 402 below the opening 380. The junction box 500 has an opening 502 aligned with the opening 380. The junction box 500 is secured to the panel base 302 by suitable fasteners (e.g., screws), by an adhesive, by plastic welding, or the like. The first panel output conductor 480 and the second panel output conductor 482 from the photovoltaic panel 402 extend into the junction box 500 and are connected respectively to a first external conductor 510 and a second external conductor 512, which exit the junction box 500 via a pair of openings 514, 516. The external conductors 510, 512 are advantageously secured to the openings 514 via a suitable adhesive (e.g., silicon adhesive) or in another suitable manner to provide strain relief for the connections within the junction box 500. After the conductors 480, 482 are connected to the conductors 510, 512, the junction box 500 is sealed with a top 520.

The external conductors 510, 512 have a sufficient size and suitable insulation for exterior use. The ends of the first external conductor 510 and the second external conductor 512 are attached to a respective first polarized connector 530 of a first polarity and a respective second polarized connector 532 of a second polarity. The conductors 510, 512 are connectable to conductors from adjacent solar panels 300 to connect the solar panels 300 in series to form a string of interconnected panels. The solar panels 300 at each end of each string of panels are connected to conductors leading to a control system (not shown) in a central location that receives the electrical outputs from the strings and provides a system power output in a conventional manner.

As discussed above, the photovoltaic panel 160 in the S-tile solar panel 100 of FIGS. 1-6 and the photovoltaic panel 402 of FIGS. 7-15 may be conventional photovoltaic panels configured to have the dimensions described above. In preferred embodiments, the photovoltaic panels 160 and 402 are constructed in accordance with a photovoltaic panel 600 illustrated in FIGS. 18, 19 and 20.

As illustrated in FIGS. 18, 19 and 20, a laminated photovoltaic panel 600 is configured as a generally rectangular panel, which is sized and shaped to fit in the depressed central portion 426 of the frame 400. Thus, the panel 600 can be handled by a construction crew without requiring any special material handling equipment. In the illustrated embodiment, the panel 600 has dimensions of approximately and has a thickness of less than approximately 0.2 inch to fit within the depth of the depressed central portion 426.

The panel 600 has a transparent upper layer 610 that faces upward and is exposed to the sun. The upper layer 610 advantageously comprises DuPont™ Teflon® fluorinated ethylene propylene (FEP) resin, which is formed into a film layer of suitable thickness (e.g., approximately 0.1 inch). The upper layer 610 provides impact protection as well as weather protection to the panel 600.

A middle layer 620 is positioned beneath the upper layer 610. As illustrated, the middle layer 620 advantageously comprises a plurality of conventional photovoltaic cells 622 arranged in an array on a suitable substrate. As shown in the cross-sectional view in FIG. 19, the middle layer 620 includes a transparent coating layer 624 formed over the photovoltaic cells 622. As discussed above, the upper layer 610 is also transparent. Thus, the photovoltaic cells 622 in the middle layer 620 are exposed to direct sunlight without being exposed to moisture and other climatic conditions and without being exposed to direct impact by feet, falling objects, and debris.

The photovoltaic cells 622 are electrically interconnected in a series-parallel configuration in a conventional manner to provide a suitable output voltage. For example, in the illustrated embodiment, 660 photovoltaic cells 622 are arranged in 2 rows of 6 cells each. The photovoltaic panel is illustrated with two flat ribbon electrical conductors 650, 652 extending from the top surface of the middle layer 620. The two conductors 650, 652 correspond to the two conductors 480, 482 in FIGS. 10 and 13. In the illustrated embodiment, the two electrical conductors 650, 652 are bent around the upper edge of the middle layer 620 and are interconnected to the external conductors 510, 512 within the junction box 500, as described above. In a particularly preferred embodiment, the electrical conductors are electrically connected to the photovoltaic cells 622 through the bottom of the middle layer 620 as illustrated in FIGS. 10 and 13 using plated vias or other conventional interconnection techniques.

The upper layer 610 is bonded to the middle layer 620 by a layer 640 of a suitable transparent adhesive, such as, for example, ethylene-vinyl-acetate (EVA). EVA is a transparent, heat-activated adhesive that is particularly suitable for securing the upper layer 610 to the middle layer 620. Preferably, the adhesive layer 640 is provided as a thin film that is positioned between the upper layer 610 and the middle layer 620. The EVA material and the use of the EVA material to bind the layers of a laminated photovoltaic cell are described, for example, in U.S. Pat. No. 4,499,658 to Lewis. In addition to acting as a binder between the upper layer 610 and the middle layer 620, the EVA layer 640 also acts as a cushion between the two layers. Other suitable adhesives, such as, for example, polyvinylbuterol (PVB), or other pottant materials, can be substituted for the EVA.

The middle layer 620 rests on a lower rigid layer 660 that supports the middle layer 620 in order to provide rigidity and strength when the panel 600 is being handled prior to installation into the frame 400 described above. In the illustrated embodiment, the lower layer 660 comprises a composite structure having a lowermost layer 662 of fiber reinforced plastic (FRP) and an uppermost layer 664 of pre-coated aluminum. For example, the FRP layer 662 advantageously comprises a polyester resin with embedded stranded glass fibers. The aluminum layer 664 is coated to reduce dirt adhesion and the like. For example, in one advantageous embodiment, the aluminum layer 664 has a thickness of approximately 0.024 inch and the FRP layer 662 has a thickness of approximately 0.079 inch to provide an overall thickness of approximately 0.103 inch. The lower layer 660 provides an advantageous combination of the light weight and flatness of the FRP layer 662 and the structural integrity of the aluminum layer 664. In one particularly preferred embodiment, a suitable composite board for the lower layer 660 is a commercially available panel marketed as AluFiber® by Euramax Coated Products BV of Roemond, The Netherlands. Such a panel is described, for example, in U.S. Pat. No. 7,083,696 to Meuwissen et al.

The middle layer 620 is secured to the aluminum layer 664 of the lower layer 660 by a layer 670 of a suitable adhesive. In the preferred embodiment, the adhesive layer 670 advantageously comprises a thin film of heat-activated EVA, as described above. In one embodiment, the two flat conductors 650, 652 from the middle layer 620 pass around the edge of the lower layer 660. Alternatively, the flat conductors 650, 652 may pass through the lower layer 660. In a further alternative, a direct connection to the photovoltaic cells 622 of the middle layer 620 may be provided through the lower layer 660 and the middle layer 620.

The upper layer 610, the middle layer 620, the lower layer 660, and the two adhesive layers 640 and 670 are stacked in the order shown in FIGS. 19 and 20 and are aligned to form the sandwich structure shown in FIGS. 18 and 19. The free ends first panel output conductor 650 and the second panel output conductor 652 are each covered with a temporary covering (e.g., a cloth tube, or the like) during the lamination process. The structure is permanently laminated in a known manner using heat and pressure. In one advantageous embodiment, the structure is laminated in a vacuum laminator in the manner described, for example, in US Patent Application Publication No. 2005/0178248 A1 to Laaly et al. In particular, the structure is first subjected to a vacuum to remove any trapped gas bubbles in the EVA adhesives. The structure is then subjected to high pressure to force the layers together as tightly as practical. The structure is then heated to a suitable temperature (e.g., approximately 160° C.) to cure the adhesives in the layers 640 and 670 and thereby permanently bond the adjacent layers. During the high temperature portion of the process, a portion of the upper layer 610 softens sufficiently to form a coating that surrounds the outer edges of the other layers, thus forming a moisture-resistant coating around the entire structure. In the illustrated embodiment, the upper layer 610 and the adhesive layer 640 secure the panel output conductors 650, 652 to the top of the middle layer 620. In an alternative embodiment, the panel output conductors 650, 652 extend from the bottom of the middle layer 620 and pass through an opening in the lower layer 660. In this alternative embodiment, the opening through the bottom layer 660 is sealed during the lamination process. In a further alternative embodiment, the panel output conductors 650, 652 are connected to the photovoltaic cells 622 on the middle layer after the lamination process is completed using known interconnection techniques.

The laminated structure is held at the high temperature for a sufficient time to cure the adhesive layers 640, 670 and to allow the upper layer 610 to soften and flow. The laminated structure is then allowed to cool to ambient temperature.

Although the resulting laminated structure is moisture resistant and is sufficiently strong to withstand the flexing that may occur during ordinary handling of the panel 600 during normal conditions, an additional structural element is added in the preferred embodiment in order to improve the moisture resistance and the structural stability. In particular, the panel 600 further includes a plastic clad metal frame. As shown in FIG. 20, the metal frame comprises a first frame half 680 and a second frame half 682. The frame halves are positioned around the edges of the laminated structure as shown in the cross-sectional view in FIG. 19 for the first frame half 680. The exposed ends of the two frame halves are butted together to form a complete frame around the perimeter of the panel 600. Although shown as two separate frame halves, it should be understood that a single length of frame material can also be used by bending the material around the edges of the panel 600 and butting the two free ends.

As further illustrated in FIG. 19, the metal frame preferably comprises a cladded aluminum extrusion with a U-shaped cross section having a wall thickness of approximately 0.05 inch. The aluminum extrusion is advantageously clad with a plastic material, such as, for example, polyvinylchloride (PVC) or thermoplastic polyolefin (TPO). In the illustrated embodiment, the two parallel legs of the U-shaped extrusion have lengths of approximately 0.1875 inch measured from the inside of the base of the extrusion. The width of the base of the U-shaped extrusion is selected to accommodate the thickness of the laminated layers of the panel 600. In the illustrated embodiment, the inside width of the base is selected to be approximately 0.18 inch.

In the illustrated embodiment, each frame half 680, 682 surrounds approximately one-half of the outer perimeter of the panel 600. As further shown in FIG. 19, each frame half is secured to the outside edge of each layer and to a portion of the upper surface of the upper layer 610 and a portion of the lower surface of the lower layer 660 by a layer 690 of a suitable adhesive. For example, in one embodiment, the adhesive layer 690 advantageously comprises a silicon adhesive, which is sufficiently strong to permanently fix the frame halves 680, 682 to the panel 600. After positioning the frame halves on the panel 600, the ends of the frame half 680 may be secured to the respective ends of the frame half 682 by welding or another suitable method if desired. As discussed above, if a single length of frame material is used, the two ends of the frame may be connected at a single location. In the illustrated embodiment, the two flat conductors 650, 652 may be sufficiently thin to be clamped between the inside of the frame half 680 and the edge of the laminated panel. Alternatively, a portion of the frame half 680 may be removed to provide room for the conductors. As a further alternative, the edges of the middle layer 620 and the lower layer 660 may be notched to accommodate the thicknesses of the flat conductors 650, 652. In preferred embodiments, the conductors 650, 652 are electrically connected to the photovoltaic cells 622 in the middle layer 620 using vias through the lower layer 660 and the middle layer 620.

After the lamination process is completed and the optional frame halves 680, 682 are secured to the edges of the panel 600, the panel 600 is positioned in the frame 400 (FIGS. 7-16) with the two panel conductors 650, 652 extending below the bottom 422 of the frame. The two conductors 650, 652 are passed through the hole 380 in the panel base 302 and through the opening 502 in the junction box 500, as shown for the two conductors 480, 482 in FIG. 13. The panel 600 is secured to the frame 400 using a suitable adhesive, as described above. The temporary coverings over the two panel output conductors 650, 652 are removed, and the two panel output conductors 650, 652 are electrically connected within the junction box 500 to the two weather-resistant external conductors 510, 512 using conventional interconnection devices. The removable top 520 of the junction box 500 is then secured over the conductor interconnection devices to provide a weather-resistant seal. The frame 400 is secured to the panel base 302 in the manner described above.

In accordance with the embodiments disclosed herein, an aesthetically pleasing roofing module combines the weather protection features and appearance of a conventional clay or concrete S-tile with the electrical energy generating capabilities of a solar cell sandwich. The roofing module are easily installed with conventional clay or concrete roofing S-tiles to include electrical energy generation capability on newly constructed roofs and can replace conventional clay or concreted roofing S-tiles to add electrical energy generation capability to existing roofs.

The present invention is disclosed herein in terms of a preferred embodiment thereof, which provides a photovoltaic panel integrated into an S-tile roofing module as defined in the appended claims. Various changes, modifications, and alterations in the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope of the appended claims. It is intended that the present invention encompass such changes and modifications. 

1. A roofing module that provides weather protection and that generates electrical power, comprising: a base comprising a plurality of raised crests and lowered pans having contours sized and shaped to match the size and shape of the contours and pans of conventional contour roofing tiles to enable the base to interlock with the conventional contour roofing tiles, the base comprising a lightweight plastic material, each crest of the base including a depressed portion; and a photovoltaic panel assembly positioned in the depressed portions of at least two adjacent crests and spanning across at least one pan between the at least two adjacent crests.
 2. The roofing module as defined in claim 1, wherein the base comprises at least three raised crests and wherein the photovoltaic panel assembly spans the at least three raised crests.
 3. The roofing module as defined in claim 1, wherein the photovoltaic panel assembly comprises: an outer frame sized to fit in the depressed portions of the base, the outer frame encompassing a depressed inner area; and a photovoltaic array sized to fit in the depressed inner area of the outer frame, the photovoltaic array have at least a first electrical output conductor and a second electrical output conductor, the base having at least one opening from a top surface to a bottom surface to provide a path for the first and second electrical output conductors through the base.
 4. A roofing module that provides weather protection and that generates electrical power, comprising: a base comprising a plurality of curved crests and curved pans having contours sized and shaped to match the size and shape of the contours and pans of conventional clay or concrete S-tiles to enable the base to interlock with the conventional clay or concrete S-tiles, the base comprising a lightweight plastic material, each crest of the base including a depressed portion; and a photovoltaic panel positioned in the depressed portions of at least two curved crests and spanning across at least one curved pan between the at least two curved crests.
 5. A method of constructing a roofing tile having an integrated photovoltaic array, comprising: constructing a photovoltaic assembly, comprising: installing a photovoltaic array in a frame having a central depressed portion sized to receive the photovoltaic array, the photovoltaic array including at least a pair of electrical conductors; and securing the photovoltaic array to the frame; and installing the photovoltaic assembly in a base having a plurality of raised crests and interposed lowered pans, the crests and pans shaped to match the shapes of a conventional contour roofing tile, comprising: positioning the photovoltaic assembly on at least first and second depressed portions of at least two adjacent crests and spanning at least one pan between the two adjacent crests; passing the at least a pair of electrical conductors through an opening in at least one of the raised crests; and securing the photovoltaic assembly to the base. 